LOCKOUT – TAGOUT TRAINING PROGRAM

Lockout/Tagout + The OSHA Standard for the Control of Hazardous Energy (Lockout/Tagout) 29 CFR covers the servicing and maintenance of machines and equipment in which the unexpected start-up or the release of stored energy could cause injury to employees.

Lockout/Tagout Definitions + Authorized employee – An employee who performs servicing or maintenance on machines and equipment. Lockout or tagout is used by these employees for their own protection.

+ Affected employee – An employee who performs the duties of his or her job in an area in which the energy control procedure is implemented and servicing or maintenance operations are performed. Lockout/Tagout Definitions

Lockout/Tagout Types of Energy Mechanical Hydraulic Pneumatic Chemical Thermal Other

Lockout/Tagout Scope and Application Covered Activities Constructing, installing, setting up, adjusting, inspecting, modifying, maintaining and/or servicing machines or equipment where employees could be exposed to the unexpected energization or release of hazardous energy

Lockout/Tagout Scope and Application Lockout/Tagout rules apply (the equipment must be de-energized and locks or tags must be applied to the energy-isolation devices) to servicing and maintenance activities when: The employee must either remove or bypass machine guards or other safety devices, resulting in exposure to hazards at the point of operation.

Lockout/Tagout rules apply (the equipment must be de-energized and locks or tags must be applied to the energy-isolation devices) to servicing and maintenance activities when: The employee is required to place any part of his or her body in contact with the point of operation of the operational machine or piece of equipment. Lockout/Tagout Scope and Application

Lockout/Tagout rules apply (the equipment must be de-energized and locks or tags must be applied to the energy-isolation devices) to servicing and maintenance activities when: The employee is required to place any part of his or her body into a danger zone associated with a machine operating cycle. Lockout/Tagout Scope and Application

Lockout/Tagout Lockout vs. Tagout If an energy-isolating device is capable of being locked out, it must be locked out unless it can be shown that a tagout system provides full employee protection.

Lockout/Tagout Types of Devices

Lockout/Tagout Written Procedures Must identify the information that authorized employees must know in order to control hazardous energy during service or maintenance.

Preparation for shutdown Shutting down the equipment Equipment isolation Application of Lockout/Tagout devices Release of stored energy Verifying equipment isolation Lockout/Tagout Written Procedures

Lockout/Tagout Preparation For Shutdown Know the types and amounts of energy that power it Know the hazards of that energy Know how the energy can be controlled

Picture 1 Picture 2 Picture 1 Picture 2 LOCKOUT-TAGOUT POLICY AND PROCEDURE CASTING MACHINE ABSOLUTELY NO PERSON IS TO CLEAN OR MAINTAIN THIS MACHINE BEFORE FOLLOWING THESE LOCKOUT-TAGOUT PROCEDURES. Turn off the machine. Place the lever of the disconnect in the off position. The disconnect is located on the East side of the column between the casting machine and the stripping saw. See picture 1. Install a hasp, tag and lock. Remove key, keeping key with you at all times while the equipment is locked out. Sign the tag and include your department and expected completion. Turn off the air using the gate valve on the column located outside of the tool room. See picture 2. Install a hasp, tag and lock. Sign the tag and include your department and expected completion date. Remove key, keeping key with you at all times while the equipment is locked out. After the air supply is turned off and locked out, release stored air by turning the valve on the east side of the machine in the off position until you hear the vibration stop. (This controls the east vibrator on the machine.) USE EXTREME CAUTION AT ALL TIMES. IF THERE ARE ANY QUESTIONS OR PROBLEMS, PLEASE CONTACT YOUR SUPERVISOR.

Lockout/Tagout Shutting Down the Equipment Shut the system down by using operating controls Follow whatever procedure is right for the equipment to avoid endangering anyone during shutdown

Lockout/Tagout Equipment Isolation Operate all energy-isolating devices so that the equipment is isolated from its energy sources. Be sure to isolate all energy sources (secondary power supplies as well as the primary supplies). Never remove a fuse instead of disconnecting.

Lockout/Tagout Application of Devices All energy-isolating devices are to be locked, tagged or both Only standardized devices can be used and they are not to be used for anything else Use a lockout device if your lock cannot be placed directly on the energy control When lockout is used, every employee in the work crew must attach his personal lock

Lockout/Tagout Release of Stored Energy Inspect the system to make sure all parts have stopped moving Relieve trapped pressure Block or brace parts that could fall due to gravity Bleed lines and vent valves open If stored energy can re-accumulate, monitor it to make sure it stays below hazardous levels

Lockout/Tagout Verifying Equipment Isolation Make sure all danger areas are clear of personnel Verify that the main disconnect switch or circuit breaker can’t be moved to the on position Press all start buttons and other activating controls on the equipment itself and return controls to the off position when the testing is complete

LOCKOUT/TAGOUT Performing the Work Look ahead and avoid doing anything that could reactivate the equipment Don’t bypass the lockout when installing new piping or wiring

LOCKOUT/TAGOUT Removing Lockout/Tagout Make sure the equipment is safe to operate by removing all tools from the work area and making sure the system is fully assembled Safeguard all employees by conducting a head count to make sure everyone is clear of the equipment. Also notify everyone in the work area that lockout/tagout is being removed Remove the lockout/tagout devices. Each device must be removed by the person who put it on

LOCKOUT/TAGOUT Contractors The outside contractor and the on-site employer must exchange lockout/tagout information Employees on site must understand rules used by the contractor Be alert for new types of lockout or tagout devices

LOCKOUT/TAGOUT Shift Changes If servicing lasts more than one shift, lockout/tagout protection must not be interrupted When the employee who applied device is not there to remove it, it can be removed only in an emergency and only under the direction of the supervisor

LOCKOUT/TAGOUT LOCK REMOVAL FORM When an authorized employee who applied a lock or tag device is not available to remove the lock or tag, then this lock removal procedure shall be used. The supervisor, acting supervisor/leadman, maintenance manager or safety manager will apply the following procedure: 1.Verify that the authorized employee who applied the device is not at the facility; 2.Make all reasonable efforts to contact the authorized employee to inform he/she that his/her lockout or tag out device has been removed; Call home, cell phone, leave message. 3.Ensure that the authorized employee has this knowledge before he/she resumes work. This can be accomplished by meeting with the employee prior to that employee beginning work activities upon their earliest return to work. A note attached to their time card is also warranted as an additional safety precaution; telephone or personal contact. 4.Complete a lock removal form and submit to the safety manager upon completion of this form. Owner of Lock :___________________________________________________________(print) Person attempting to contact Owner of Lock/Tag___________________________(Print/Sign) Equipment Locked Out:__________________________ Dept:_________________________ Date of Removal: ________________________________ Time: _________________________ Steps taken to contact Owner of Lock/Tag: _____________________________________________________________________________________ Reason for removing Lock or tag:________________________________________________________________

Lockout/Tagout Lockout/Tagout Devices Identifiable – Locks and tags must clearly identify the employee who applies them. Tags must also warn against hazardous conditions if the machine or equipment is energized and must include a legend such as: DO NOT START, DO NOT OPEN, DO NOT CLOSE, DO NOT ENERGIZE, DO NOT OPERATE.

Lockout/Tagout Periodic Inspections Inspections must be performed at least annually to assure that the energy control procedures continue to be implemented properly and that the employees are familiar with their responsibilities.

Lockout/Tagout Periodic Inspections Supervisors are responsible for conducting this annual inspection and they must certify that the inspections have been performed. The certification must identify the machine or equipment, the date of the inspection, the employees included, and the name of the person performing the inspection. Must identify any deficiencies or deviations and correct them.

Lockout/Tagout Scope and Application Activities Not Covered Minor tool changes and adjustments, and other minor servicing activities that take place during normal operating production operations which are routine, repetitive, and integral to the use of that production equipment, as long as workers are effectively protected by alternative measures.

Lockout/Tagout Scope and Application Activities Not Covered Work on cord and plug connected equipment if the equipment is unplugged from the energy source and the authorized employee has exclusive control of the plug.

Lockout/Tagout Scope and Application Activities Not Covered Hot tap operations that involve transmission and distribution systems for gas, steam, water, or petroleum products on pressurized pipelines if continuity of service is essential, shutdown of the system is impractical, documented procedures are followed, and employees are effectively protected by special equipment.

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